Extendable sleeve for poured concrete deck

ABSTRACT

A tubular passage for poured concrete decks has an intumescent tube held in a two-part, clamshell base by a bottom clip. A first tube engages the base&#39;s top to clamp a funnel shaped, diaphragm seal to the base. The first tube has spaced, radially extending, parallel ridges at predetermined distances from the base. Longitudinal channels separate the ridges. An extension tube has inward extending lugs passing along the channels to engage various ridges when rotated to fix the passage length. The extension engages the base bottom for corrugated deck supports. A cap with repositionable, locating filaments closes either tube.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of application Ser. No. 13/840,003,titled Extendable Sleeve for Poured Concrete Deck, filed Mar. 15, 2013,the complete contents of which are hereby incorporated by reference.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND

Concrete floors in multistory buildings are poured onto flat plywooddecks that are later removed, or poured onto corrugated sheet metalsupports that are left in place. In both cases passages through theconcrete decks are needed for various plumbing pipes, electricalconduits, ventilation tubes, etc. In the event of fire or flooding,these passages through the concrete must be sealed in order to preventpassage of air, smoke, fire or water. Current fire and smoke seals usean intumescent material that involves taking flat strips of intumescentmaterial and fastening it around a cylindrical container ofpredetermined diameter using adhesives or other mechanical fasteners.The intumescent material often includes a graphite or fibrous materialthat can be messy and hazardous to handle and ingest, and oftencarcinogenic. Fastening the flat strips to the passage tubes is laborintensive, prone to errors and may raise health concerns. Because theintumescent material has a limited expansion, and because manyapplications require effective internal smoke and water sealing, thecontainers are generally made to order for specific pipe sizes. Further,because of the variable thickness of concrete slabs specified by buildercontractors, manufacturers are forced to either custom build thecontainer hardware or to supply containers in large increments thatforce customers to buy extra kits or cut the container on-site. In anyevent, current options do not allow economically effectivemanufacturing-to-specification solutions. Upon installation, the pipesactually used may differ from those initially planned or may be offsetfrom the center more than the expansion of the intumescent material canaccommodate, so the prefabricated, size specific fire seals may not fit,or fit as well as intended or needed, or may not work as well asdesigned during actual use. There is thus a need for an improved fireseal and container for intumescent material that will accommodate awider variety of pipe diameters within a single device be more easilyassembled and installed, and better suit variations in pipe location andslab thickness than devices currently used.

The passages through the concrete are formed by fastening a passagetube, typically plastic or metal to the support before the concrete ispoured. The concrete decks vary greatly in thickness from four to eightinches, but may be as thin as two inches and as thick as 18 inches ormore. Current passage tubes are premade to specific diameters andlengths, making it difficult to stock a sufficient supply for use and toaccommodate variations in the passage tubes at the job site. There isthus a need for a more flexible length passage tube able to accommodatepipes of varying diameters.

The tubes must be fastened to the plywood support, or have a larger baseto span enough corrugations to provide a stable tube support, especiallyfor smaller diameter, longer passage tubes. Providing a large basesuitable for corrugated supports is expensive and unnecessary forplywood supports. Moreover, several pipes may sometimes be clusteredtogether when passing through the floor and in such cases the individualpassage tubes need to be placed close together at distances driven byCISPI standards. If the passage tube has a large base for use on acorrugated support, it becomes difficult to achieve the desired spacingwhen the large support is used on either plywood or corrugated supports.There is thus a need for an improved tube support more suitable for thedifferent support applications.

The passage tubes are provided in different lengths to accommodate thevariable thickness of the concrete decks. Long passage tubes aresometimes cut shorter, wasting material and often resulting ininaccurate cuts as the worker may measure wrong. Sometimes an extensioncan be added to a shorter passage tube to increase the overall length,but again workers can measure wrong, resulting in non-compliant passagesthrough the concrete. Also, the extended tubes may be hit, kicked orstood on and in such cases extension tubes may break. There is thus aneed for an improved passage tube with a sturdier, easily adjustedlength.

In addition to a smoke and fire seal the passages through the concretemust provide a water seal around the pipes or conduits passing throughthe passage tube. Flat, plastic or rubber sheets are used with holes cutout for the pipe to pass through and these are also installed in thepassage tube at the time the passage tubes are made. If the pipes aretoo large for the holes the sheets tear, if the pipes are too small theseal is poor and if the pipes are offset from the holes in the sheetsthen inadequate seals may formed. There is thus a need for an improvedwater seal in passage tubes.

When the concrete deck is poured around the passage tubes the upper endof the tubes are blocked to prevent concrete from filling the passagetube. Mechanical trowels and riding trowels are used to finish theconcrete surfaces of the poured decks and the closed ends of the tubesare often covered with a thin layer of concrete in doing so. Theconcrete covering makes it difficult to locate the passage tubes.Workers sometimes tape nylon strands to items over which concrete ispoured so the strands extend out of the concrete surface after finishingand bend for the troweling machines. But taping strands to things istime consuming, may be unintentionally omitted or not planned at all,and the tape may tear lose or otherwise fail to restrain the strandsduring pouring of the concrete or troweling. There is thus a need for animproved way to locate passage tubes in freshly poured concrete floors.

The passage tubes may need to be configured differently depending onwhether they are to contain metal or cast iron pipes or plastic pipes,in part because the water seal with the outside of a cast iron pipe hasdifferent requirements than for plastic or copper pipes. For example,exterior pipe diameters differ significantly between pipe types of eventhe same nominal internal size. Workers can sometimes look inside thepassage tube to see the opening size in the water seal but that is timeconsuming, and invites error from judging opening diameters by visuallylooking down a dark tube of varying length. There is thus a need for animproved way to allow workers to identify the types of pipes a passagetube is designed to accommodate.

BRIEF SUMMARY

An assembly is provided to form an adjustable length, tubular passage inpoured concrete decks. The assembly has a tubular cylinder ofintumescent material held in a two-part base by a clip supporting thebottom of the tubular cylinder of intumescent material and fastened tothe base. A first, cylindrical tube engages the base's top to clamp adiaphragm seal against the base. The seal has a pipe opening and afunnel shape to accommodate pipe offsets and to better seal against thepipe. The first tube has spaced, radially extending, parallel ridges atpredetermined distances from the base. Cutting between the ridgesadjusts the length of the tubular passage to known lengths. Longitudinalchannels separate the ridges into first and second sets of ridges.Printed indicia in the channels or in the grooves between adjacentridges can state the lengths. The two sets of ridges can be at differentdistances from the base for greater variability of length adjustment. Acylindrical extension tube fits over the first tube and has inwardlyextending lugs on opposing sides of a first end of the extension tube.The lugs pass along the longitudinal channels with the extension tubebeing rotated to engage the lugs with various ridges to adjustably fixthe passage length to the end of the extension tube. A second end of theextension tube optionally engages the base bottom for use withcorrugated supports. A cap with repositionable locating filamentsoptionally closes the either the first extension tube or the first tube,depending on need. The locating filaments are attached to the undersideof the cap and extend inside nested first tube and extension tube forshipment, with the filaments being repositioned to connect to theoutside of the cap and extend along the longitudinal axis during use.The locating filaments connect to the cap below the outer surface so thefilaments bend during troweling of the concrete and extend above thefinished concrete surface to allow users to locate the tubular passageafter concrete finishing.

In more detail, there is advantageously provided a tubular passageassembly for poured concrete decks formed on a support surface. Theassembly includes a base having a cylindrical sidewall with an upper endand an opposing bottom end and extending along a longitudinal axis. Theupper end of the sidewall has an inward extending upper flange defininga circular opening encircling the longitudinal axis. The lower end ofthe base has an outward extending base flange to support the base on thesupport surface during use. A cylindrical tube of intumescent materialencircles the longitudinal axis and fits inside and adjacent to thesidewall and is restrained from movement in a first direction along thelongitudinal axis by the upper flange. A retaining clip has an annularportion abutting the bottom of the tubular cylinder of intumescentmaterial to restrain the tubular cylinder of intumescent material frommovement in a second direction along the longitudinal axis. Theretaining clip has a plurality of tabs extending through the basesidewall to restrain movement of the retaining clip along thelongitudinal axis during use.

In addition to the base assembly, the tubular passage assembly mayinclude a flexible diaphragm seal having an outer periphery engaging anupper end of the base and having an inner periphery defining an openingencircling the longitudinal axis during use. A portion of the diaphragmadjacent the inner periphery has a funnel shape extending out of a planeorthogonal to the longitudinal axis through the outer periphery.

In further variations, the first tube has opposing upper and lower endswith the lower end configured to engage the base. The first tube alsomay have an inward extending flange adjacent the lower end configured toengage the periphery of the diaphragm and press it against the base toform a fluid tight seal when the first tube is engaged with the base.The first tube may further includes a first set of parallel ridgesextending outward from the first tube with each of the first ridges in aplane orthogonal to the longitudinal axis and the first set of ridgeseach extending less than half way around the first tube. The first tubemay also include a second set of parallel ridges extending outward fromthe first tube with each of the ridges in a plane orthogonal to thelongitudinal axis. The second set of ridges each extends less than halfway around the first tube and located on an opposing side of the firsttube than the first set of ridges. The first and second ridges each haveends spaced apart to define first and second longitudinal channels onopposing sides of the first tube. The first tube may further include afirst set of visible indicia adjacent a plurality of the first set ofridges where the indicia defines a distance from the bottom of the baseto the visible indicia associated with each of the plurality of thefirst set of ridges. The first tube may also have a second set ofvisible indicial adjacent a plurality of the second set of ridgesdefining a distance from the bottom of the base to the visible indiciaassociated with each of the plurality of the second set of ridges, withat least one of the first and second set of indicia indicating adistance specified in metric or English distance units.

In further variations, a plurality of the ends of two adjacent ridges inthe first set of ridges are joined by first axially extending endsegments with the first axially extending end segments joining only twoadjacent ridges. A plurality of second axially extending end segmentsmay join adjacent ridges which ridges are each joined to a different oneof the first axially extending end segments. The first axially extendingend segments are located a first circumferential distance from a centerof the first channel and the second axially extending end segmentslocated a second circumferential distance from the center of the firstchannel with the second circumferential distance being greater than thefirst circumferential distance to form a first circumferential recess ateach second axially extending end segment. Further, a plurality of theends of two adjacent ridges in the second of ridges may be joined bythird axially extending end segments with the third axially extendingend segments joining only two adjacent ridges. A plurality of fourthaxially extending end segments may join adjacent ridges which are eachjoined to a different one of the third axially extending end segments.The third axially extending end segments are located a thirdcircumferential distance from the center of the first channel and thefourth axially extending end segments located a fourth circumferentialdistance from the center of the first channel, with the fourthcircumferential distance being greater than the third circumferentialdistance to form a second circumferential recess at each fourth axiallyextending end segment.

In still further variations, the base may have an outwardly extendinglimit stop and the first tube has a tab located to hit the limit stop asthe first tube engages the base so as to position the first tube a knowndistance from a bottom of the base and ensure proper compression of thediaphragm seal. Further, the base may have external screw threadsthreadingly engaging internal screw threads on the lower end of thefirst tube to engage the first tube to the base, with the base and firsttube each having a motion limit stop located to engage when the firsttube is at a predetermined distance from the bottom of the base.Further, the base may be formed of two segments separated along a planethrough the longitudinal axis but fastened together to form the baseafter the tubular cylinder of intumescent material is inserted into atleast one segment of the base.

In still further variations, the tubular passage assembly may include afirst extension tube having opposing top and bottom ends with the topend threaded internally and the bottom end threaded externally with thesame threads as the top end. The bottom end of the first extension tubehas first and second locking lugs each extending inward from a differentopposing side of the first extension tube with the first and secondlocking lugs being sized and located to slide along the first and secondchannels, respectively. Rotation of the first extension tube places eachlocking lug between two adjacent ridges of one of the first or secondsets of ridges. Further, the upper end of the first extension tube mayhave internal threads sized to threadingly engage external threads onthe cap with the first extension tube being large enough to fit over thefirst tube. This first extension tube may also act as a lower extensionin cooperation with threads formed in the base located to threadinglyengage threads on one end of the extension tube. Still further,additional extension tubes may be threaded into the first extension tubeif needed, to further lengthen the tube.

In further variations, the flexible diaphragm is made of silicone andhas sidewalls curving upward away from the base and toward thelongitudinal axis, with the curved sidewalls located intermediate theinner and outer periphery. The base flange may extend along at least twoopposing sides of the base and further includes at least a firststabilizing plate configured to releasably fasten to one of the at leasttwo opposing sides of the base flange and restrain rotation of the upperend of the base toward the juncture of the base flange with thestabilizing plate.

An improved cap is also provided for use with the tubular passageassembly. The cap has a circular top having an upper and lower side withan annular skirt depending therefrom. First and second latches eachextend inward from an opposing side of the skirt. The latches areconfigured to releasably engage one of the ridges on the outside of thefirst tube in order to fasten the cap to the first tube. Also, the capmay have external threads for attaching to the first extension tube. Thecap has a connector on at least the upper side of the top with theconnector located in a recess. A filament base has at least one filamentextending therefrom and is configured to releasably engage the connectorto hold the at least one filament generally parallel to the longitudinalaxis. The juncture of the filament to the filament base being locatedbelow the upper side of the top and sufficiently far from the recessedge so that the at least one filament can be troweled against the upperside of the top and not break, the filament having a length sufficientto be visible after the cap is covered with a thin layer of troweledconcrete during use.

There is also provided a kit for forming a tubular passage along alongitudinal axis for passage of a pipe through a poured concrete deck.The kit includes a base assembly having a base formed of two opposinghousing portions fastened together to form a cylindrical sidewallportion containing a tubular cylinder of intumescent material adjacentthe cylindrical sidewall portion. The tubular cylinder of intumescentmaterial encircles the longitudinal axis and has its motion limited in afirst direction along the axis by the housing and has movement in theopposing direction along the axis limited by a clip engaging thehousing. The kit may include a flexible diaphragm seal having a centralopening selected to seal against a range of pipe diameters during use.The seal has a funnel portion between an outer periphery and the centralopening. The kit may also include a first cylindrical tube configured tofasten to a top of the base assembly during use and encircle thelongitudinal axis during use. The first tube and base are configured toclamp a periphery of the flexible diaphragm between them sufficiently toform a fluid tight seal.

In further variations, the first tube of the kit has a plurality ofoutwardly extending, equally spaced ridges on an exterior surfacethereof and extending along a majority of a length of the first tube.The kit also may include a first cylindrical extension tube having afirst end configured to fit over the first tube and having at least onelug configured to engage a selected one of the plurality of outwardlyextending ridges to releasably fasten the first extension tube to thefirst tube. The kit may further include a first tube that fastens to thetop of the base by a double lead threaded connection. The base may haveinternal, double lead threads on a bottom thereof which threads encirclea lower portion of the tubular cylinder of intumescent material and areconfigured to threadingly engage mating threads on the first cylindricalextension tube.

The first tube may also form a separate improvement. The first tube mayform a tubular passage along a longitudinal axis for passage of a pipethrough a poured concrete deck. The first tube may include a tubularcylinder having an opposing upper and lower ends extending along thelongitudinal axis during use. The cylinder has a first diameter along amajority of its length with a larger diameter lower end and internalthreads around the inside of the larger diameter lower end. The cylindermay have a first plurality of parallel ridges extending radially outwardalong a majority of a length of the cylinder and a second plurality ofparallel ridges extending radially outward along a majority of a lengthof the cylinder and axially offset from the first set of ridges. Thefirst and second sets of ridges are preferably separated by first andsecond channels extending parallel to the longitudinal axis. In furthervariations, a plurality of the ridges in the first set has distal endsjoined by vertical segments at the distal ends of said plurality ofridges.

In the above tubular passages and kits, for use on corrugated supports,a hole is cut through the corrugation and the base positioned over thehole. An extension tube the same as the first extension tube is passedupward through the hole in the corrugation and fastened to the bottom ofthe base. Preferably the base has mating screw threads encircling thetubular cylinder of intumescent material and thus outward of thatcylinder and accessible from the lower side of the base. To enable thescrew threads to extend into the base and encircle the tubular cylinderof intumescent material the retaining clip is offset so that the tabsbend upward to form an offset accommodating the bottom screw threadswith the tabs then extending outward through openings in the cylindricalsidewalls of the base that encircle the tubular cylinder of intumescentmaterial. As needed, a removable adhesive cover or cap is placed overthe bottom of the base to keep debris from entering the base duringshipment, during installation, during pouring of the concrete and duringapplication of fire retardant spray. The removable adhesive cover or capmay be removed and placed on the open end of an extension tube that isscrewed into the bottom of the base if desired.

The base flanges may have two removable tabs formed in the base. One tabmay indicate metal and the other plastic. If the shaped diaphragm andbase assembly are selected for use with metal pipes passingtherethrough, then the plastic tab is removed so that a user can seefrom looking at the tab on the base that the passage tube is intendedfor use with metal pipes. If the shaped diaphragm is selected forplastic pipes then the metal tab is removed so that a user can see fromlooking at the tab on the base that the passage tube is intended for usewith plastic pipes. The indicia indicating metal or plastic pipe ispreferably visible from at least the upper side and preferably visiblefrom both the upper and lower sides of the base. Alternatively, theindicia may consist of color-coded inserts installed in openings in thebase flange.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the invention will becomemore apparent in light of the following discussion and drawings, inwhich like numbers refer to like parts throughout, and in which:

FIG. 1 is an exploded perspective view of an extendable sleeve forforming a tubular passage in a poured concrete floor;

FIG. 2 is a top perspective view of a base of FIG. 1;

FIG. 3 is a bottom perspective view of the base of FIG. 2;

FIG. 4 is a top perspective view of an assembly including a base and afirst tube of the extendable sleeve of FIG. 1;

FIG. 5 is a top perspective view of the assembly of FIG. 4 furtherincluding a first extension tube;

FIG. 6 is a sectional view of the assembly of FIG. 5, taken along 6-6 ofFIG. 5;

FIG. 7 is a partial perspective view of a portion of FIG. 6 showing thejuncture of the first tube and the extension tube;

FIG. 8 is a partial perspective view of a portion of FIG. 5 showing thejuncture of the first tube and extension tube;

FIG. 9 is a top perspective view of the extendable sleeve of FIG. 1 witha second extension tube thereon;

FIG. 10 is a top perspective view of the extendable sleeve of FIG. 1;

FIG. 11 is a bottom perspective view of the base and first tube and capof FIG. 1;

FIG. 12 is a section view of the extendable tube of FIG. 6 with a capand locating filaments thereon in a position for shipping;

FIG. 13 is a top perspective view of a cap of FIG. 1;

FIG. 14 is a bottom perspective view of the cap of FIG. 11, withlocating filaments in a shipping position;

FIG. 15 is a top exploded perspective view of a base, first tube and capof FIG. 1 with the first tube cut to a very short length;

FIG. 16 is a bottom, exploded, perspective sectional view of the baseand cap of FIG. 15;

FIG. 17 is a top, exploded perspective view of a the extendable sleeveof FIG. 1 with a bottom extension tube;

FIG. 18 is a perspective view of the juncture of a corrugated formstabilizing plate with the base of FIG. 17;

FIG. 19 is a bottom perspective view of the assembly of FIG. 17;

FIG. 20 is a bottom perspective view of the assembly of FIG. 17 but withthe bottom cover removed;

FIG. 21 is a bottom, perspective section view of the diaphragm seal ofFIG. 1;

FIG. 22 is a section view of the extendable sleeve of FIG. 17 on acorrugated support;

FIG. 23 is a sectional view taken along 23-23 of FIG. 24 a;

FIG. 24a is a top view of two halves of the base housing, each of adifferent base, joined together;

FIG. 24b is a side view of the joined half-housings of FIG. 24 a;

FIG. 25a is a perspective view of a tubular cylinder of intumescentmaterial having undulating sides;

FIG. 25b is a perspective view of a tubular cylinder of intumescentmaterial having undulating a smooth outer surface and ridged inwardfacing surface having triangular ridges;

FIG. 25c is a perspective view of a tubular cylinder of intumescentmaterial having undulating a smooth outer surface and ridged inwardfacing surface having rectangular ridges

FIG. 25d is a perspective view of a tubular cylinder of intumescentmaterial having a shaped upper and outer surface and a smooth interiorsurface;

FIG. 26a is a perspective, sectional view taken along section 26 a-26 aof the base of FIG. 26b ; and

FIG. 26b is a perspective view of a further embodiment of the base ofFIG. 1.

DETAILED DESCRIPTION

Referring to FIGS. 1-20 a passage tube assembly is provided having abase 12 formed of a housing 14 having two-parts 14 a and 14 b whichclamp radially about a longitudinal axis 16 of the passage tube assembly10 and base 12, with fasteners 18 a clamping mating bosses 18 b, 18 c onopposing housing parts together in order to secure the housing parts 14a, 14 b together. The base preferably has a flange 17 extending outwardfrom the lower end of the base 12. As used herein, the relative termsinner and outer, inward and outward, are with respect to longitudinalaxis 16. The relative terms above and below, upper or lower, upwards anddownwards are also relative to the position along longitudinal axis 16with respect to flange 17 on base 12 in the orientation of FIGS. 1 and4-6, so that housing 14 and passage tube assembly are above base flange17.

Referring especially to FIGS. 1-3 and 6, the housing parts 14 a, 14 beach have a curved sidewall extending along the longitudinal axis 16 andan inwardly extending lip 20 on an upper end to restrain upward axialmovement of an tubular cylinder 22 of intumescent material placed insidethe housing 14. The housing parts 14 a, 14 b may each have a lower lip(not shown) at a lower end to restrain downward axial movement of thetubular cylinder 22 of intumescent material, in which case the tubularcylinder 22 of intumescent material is placed in one part of the base 12or housing parts 14 a, 14 b before the two parts are joined and fastenedtogether to form the base 12. But using two, (one upper and one lowerlip) may complicate molding so preferably only one lip is used, upperlip 20, with the tubular cylinder 22 of intumescent material held at thebottom of the base 12 by a retaining clip 24 having tabs 26 that passthrough mating openings 28 in each of the two-part housing 14 as the twoparts of the housing are assembled.

The retaining clip 24 has an annular bottom portion 30 to hold thebottom of the tubular cylinder 22 of intumescent material, with theannular bottom portion being offset axially from four extending tabs 26for reasons discussed later. After assembly, the tabs 26 extend from theinside to the outside of housing 14 and the tabs are then bent to lockthe retaining clip 24 in place so the tubular cylinder 22 of intumescentmaterial is constrained on three sides by the annular bottom portion 30of the clip 24 and the base's sidewall 19 and upper lip 20, so thatthermal expansion of the tubular cylinder 22 of intumescent material isdirected generally inward toward longitudinal axis 16.

The two parts of housing 14 a, 14 b are fastened together by snapslocks, threaded fasteners, other mechanical locks, or adhesives, withscrews 18 being illustrated in the Figures. The lower end of the base 12has flange 17 extending outward from the base's sidewall 19 with holes32 in the flange to allow the flange to be nailed, screwed or otherwisefastened to a support 33. That provides an easily molded housing 14 thatmay be quickly assembled to form base 12, with retaining clip 24 holdingthe tubular cylinder 22 of intumescent material in place within the base12.

The tubular cylinder 22 of intumescent material may be a continuousannular ring or a split ring with two adjacent ends separated by a slot.However, the cylinder 22 may also be formed by methods obtained fromprior art, including rolled shapes of intumescent materials. The tubularcylinder 22 of intumescent material is preferably preformed for easy ofassembly. The tubular cylinder 22 of intumescent material may be formedin a corrugated shape to expand faster and to expand to a greaterdistance than previously achieved.

Referring to FIGS. 1-3 and 11-12, the upper end of the base 12 may haveexternal threads 34 so that a lower end of a first sleeve or tube 36,preferably a graduated tube 36, can threadingly engage the base 12 viamating internal threads 35 (FIG. 12) on the inner surface of the firsttube 36 adjacent the lower end of the first tube 36. By graduated, it ismeant the outer surface of the tube 36 has physically protruding lengthindicators, described later. Advantageously, the cylindrical wallforming first tube 36 is generally concentric with the lip 20 on thebase 12, requiring a lateral, outward offset, stepped or enlargedportion 37 so that the bottom end of first tube is larger in diameterthan the remaining upper portion of tube 36, with the internal threads35 formed on that enlarged stepped portion.

The threads 34 are preferably double lead threads, with one lead on eachhalf 14 a, 14 b of the housing. Thus, the mating threads 35 on firsttube 36 are also preferably double lead threads. A rotation stop 38 a onsidewall 19, just below the threads 34 abuts a mating stop 38 b on thebottom end of first tube 36 in order to limit the engagement of matingthreads on the base 12 and first tube 36 and also accurately positionsthe first tube 36 relative to the base 12 and particularly positions thetube 36 relative to base flange 17.

As best seen in FIGS. 1, 6, 12, 16 and 21, the first tube 36 clamps anouter periphery of a shaped seal diaphragm 40 against the cylindricalwall forming base 12, preferably against the inwardly extending upperlip 20 of the base 12. The first tube 36 may have an inwardly extendingflange 39 (FIG. 12, 16) located concentric with the location of upperlip 20 or another portion of base 12 to squeeze and seal against theseal 40. The inward flange 39 is preferably at the juncture of theenlarged or stepped portion 37 with the remainder of the first sleeve ortube 60 so as to provide a larger radially extending surface to abut theperiphery of diaphragm seal 40. The depending skirt 45 of the diaphragmseal 40 is advantageously located between an inner surface of thestepped portion 37 and an outer surface of the base 12 adjacent lip 20.Thus, the lip or skirt 45 on the diaphragm seal 40 resists radiallyinward motion when it is clamped between the base 12 and the first tube36. That provides a strong, fluid seal for the outer periphery ofdiaphragm seal 40 with the mating base 12 and first tube 36. Theperiphery seal is believed capable of meeting and preferably exceedingregulatory fluid retention requirements.

The diaphragm 40 has a central opening 42 that is preferably surroundedby an inclined or curved, funnel shaped wall 44 that encircles anddefines opening 42. As used herein, the term “funnel shaped” includeswalls that are straight and inclined (e.g., like a cone) and alsoincludes curved walls. The funnel shaped wall 44 in turn preferablyjoins a generally planar annular portion 43 having a depending skirt 45at an outer periphery thereof. The opposing surfaces of the base 12 andthe first tube 36 advantageously, but optionally have sealing surfaces,such as opposing tongue-and-groove configurations, in order to furtherensure the parts sealingly engage opposing surfaces of the diaphragmseal 40. The opposing surfaces of the base 12 and first tube 36 clampthe outer periphery of the diaphragm seal 40 adjacent the dependingflange 45 and in the flat annular portion 43 near the juncture with theflange 45.

In use, a pipe extends along longitudinal axis 20 and through theopening 42 which seals against the outer surface of the pipe. Theopening 42 is selected to be sufficiently smaller in diameter than theouter diameter of the pipe that a fluid tight seal is establishedmeeting and preferably exceeding regulatory requirements. The pipebasically stretches the elastic opening 42 and funnel shaped portion 44to form a friction seal with the pipe. Further, the base 12 and pipe arefit relative to each other so the pipe passes through the diaphragm seal40 in the axial direction along which the funnel shaped portion 44 isdirected, the upward direction. That allows fluid collected between theinside of the first tube 36 and the outside of the pipe to press thefunnel shaped portion 44 against the pipe further increasing the sealingforce. As desired, the funnel shaped portion 44 may have concentricridges encircling the opening 42 in order to increase the grip betweenthe funnel shaped portion 44 and the pipe during use, and to furtherincrease the water seal between the parts.

The funnel shape wall 44 also allows lateral movement of the opening 42in order to accommodate pipe locations that are offset from the desiredcenter position along axis 16. The curved, funnel walls 44 also allowmore flexibility in the opening 42 before tearing and may lie againstthe pipe to provide a better seal. An elastomeric or rubber diaphragm 40is believed suitable, preferably silicon or neoprene. The seal 40 ispreferably made of a thin, flexible material. As used herein for theseal 40, thin means a thickness between opposing surfaces that is lessthan about 10% the diameter of the seal at the outer periphery andpreferably less than 5% of the diameter of the seal at the outerperiphery. The opening 42 is smaller than the diameter D of the smallestpipe that is intended to be passed through the tubular passage assembly10 and seal 40 so the pipe stretches the opening 42 and creates africtional grip to help form a water seal. Pipe diameters D from 0.5inches to 4 inches are common, with larger diameters D up to 8 inchesbeing less common.

Referring to FIGS. 1 and 4-12, the first tube 36 has a first and secondset of outwardly extending ridges 46, 48, respectively formingintervening slots between the respective ridges of each set. The firstridges 46 and intervening first slots each extend about half way arounda first side or first partial circumference of the first tube 36. Thesecond set of ridges 48 and second slots between those second ridgesextend about half way around the opposing, second side or second partialcircumference of the first tube 36. The ridges 46, 48 on the first andsecond sides of the first tube 16 are equally spaced apart about thedistance of a saw blade used by construction workers. The first set ofridges are offset from the second set of ridges, with the first set ofridges being spaced in fractions of an inch and the second set of ridgesbeing spaced metrically, preferably in millimeters. Visible indicia 50(FIGS. 1 & 7) on the first tube 36 discloses a distance from the bottomof the base to each slot, or to the bottom of each ridge (46, 48)forming the slot, so that a worker can cut the first tube 36 to desired,known length by cutting at a slot, with the saw blade guided by theopposing ridges 46 or 48 on each side of the slot. The ridges may beviewed as graduations on the outside of the first tube 36, which is whythe first tube 36 may also be referred to as a graduated tube.Regardless of terminology, the graduated ridges 46, 48 and printedindicia 50 identify a plurality of graduated distances from the bottomof the flange 17 of base 12.

The first and second sets of ridges 46, 48 and their intervening slotsare in radially aligned planes extending orthogonal to axis 16. Thesesets of ridges 46, 48 are separated by first and second longitudinalchannels 52 a, 52 b located on opposing sides of the first tube 36. Asdesired, the printed indicia 50 may be located in one or bothlongitudinal channels 52 a, 52 b, or on the outer sides of cylinder 36in the spaces between adjacent ridges 46 or 48. The ends of two adjacentridges 46 or two adjacent ridges 48 within each set of ridges may bejoined by axially extending end segments 54 (FIG. 7), with alternatingpairs of ridges joined by offset end segments 56 (FIG. 7) that areoffset circumferentially a short distance from end segments 54 eachother to form staggered axial end connections. A latching protrusion 58(FIG. 7) may extend axially from or near the axially extending endsegments 54 to form a snap lock connection described later.

A first extension tube 60 is provided with threads 64, 66 on opposinglower and upper ends of the tube, respectively, preferably with externalthreads on one end and internal threads on the other end. The threads64, 66 are preferably double lead threads with one lead beginning on anopposing side of the tube 60 as the other lead. The depicted embodimenthas external lower threads 64 and internal upper threads 66. Oppositethe external threads 64 on the lower end of extension tube 60 are firstand second, locking lugs 70 (FIG. 6) extending inward from opposinginner sides of the extension tube 60 at or adjacent to the end of theextension tube 60. Each locking lug 70 is sized in its circumferentialdirection to fit within one of the first and second channels 52 a, 52 bso the extension tube 60 can slide along the outside of the first tube36. The locking lugs 70 are sized fit into the gaps formed by thestaggered axial end segments 54, 56 so that rotating the first extensiontube 60 places at least one and preferably both of the locking lugs 70between two adjacent ridges 46 or 48 on the first tube 36. The latchingprotrusion 58 advantageously engages a mating recess on the upper edgeof the adjoining locking lug 70, to snap-lock the extension tube 60 tothe first tube 36. The ends of the ridges 46, 48 and the axial endsegments 54, 56 restrain rotation of the lugs 70 and also provide anaxial strength if a worker strikes or steps on the extension tube 60.Thus, the lugs 70 hit end segments 54, 56 to stop axial movement of thetube 60 until the lugs are rotated into the channels 52 a, 52 b.

The first extension tube 60 is a known length L and by viewing thedistance reflected by the visible indicia 50 marked on the outer sidesof the first tube 36 and aligned with the lower edge of the firstextension tube 60, the length from the bottom of flange 17 on the base12 to the upper, distal end of the extension tube 60 is known. Forexample, if the lower edge of extension tube 60 is aligned with theridges 46 or 48 corresponding to printed indicia 50 indicating adistance of 3 inches from the bottom of flange 17 on base 12, and if theextension tube 36 is 5.5 inches end to end, then the distal end of thefirst extension tube 70 is 3+5.5=8.5 inches from the bottom of base 12.That system allows easy adjustment of the height of the passage tubeassembly.

When the first extension tube 60 is fastened to the first tube 36 thefree or distal end of the extension tube 60 can be closed off or anotherextension tube 60 can be added. If another extension tube 60 was addedto the above example, the distance of passage tube assembly would be3+5.5+5.5=14 inches from the flange 19 to the end of the secondextension tube 60. Additional extension tubes may be added by use of themating threads 66 on the distal end of the first extension tube 60, asseen in FIG. 9. Again, the extension tubes 60 are each of known lengthand preferably all the same length so the height to the end of a stackof extension tubes can be readily determined by adding one or moreextension tubs 60. Depending on how the end of the distal extension tube60 is closed, some length accommodation may need to be made toaccommodate for the closure.

The end of the last extension tube 60 can be closed by a cap 72 having askirt that fits inside or outside the distal end of the last extensiontube 60, but preferably the cap 72 has threads 74 configured tothreadingly engage 66 on the end of extension tube 60. The cap threads74 are thus preferably also double led threads, with one lead beginningon an opposite side of the cap as the other lead. Since the threads 66are preferably internal threads the cap threads 74 are preferablyexternal threads, preferably on a depending skirt 75 depending from aslightly larger annular top that results in an annular flange 76abutting the distal end of the extension 60 to more accurately definethe length of the tubular passage assembly 10 when the flange 76 abutsthe distal end of extension tube 60, increasing the length of tubularpassage assembly 10 by the axial length of the flange 60. The annularflange 76 abutting the distal end of extension tube 60 also provides astronger assembly to transfer forces along longitudinal axis 16 throughthe extension tube 60.

Referring to FIGS. 5-8 and 15-16, if the first tube 36 is cut to lengthbetween ridges 46, 48 and no extension tube 60 is used, or if the firsttube 36 is not cut but no extension tube 60 is used, then the cap 72 isfastened to the ridges 46, 48 on the first tube 36 by one or morelatches or lugs or snaps 78 (FIG. 14-16) extending inward from thecylindrical skirt on which the threads 74 are formed. The lugs 78 mayoptionally, but less preferably correspond to lugs 70 and fit withinchannels 52 a, 52 b and engage ridges 46, 48 in the same or similarmanner, the description of which is not repeated. Preferably though, thelugs 78 may take the form of snap locks with a surface inclined toresiliently bend and slide over the ridge 46, 48 on the distal end ofthe first tube 36 and latch into the groove between the adjacent ridges.Opposing ends of lugs 78 may be bounded by slits through the skirt 75 onwhich the lugs are formed to provide a resilient latch that can bend toslide over the ridges 46, 48. The skirt 75 of the cap 72 thus has areleasable fastening mechanism on both sides of the skirt, with capthreads 74 on the outer surface of the skirt and snap locks or lugs 78on the inner surface of the skirt.

Referring to FIGS. 1 and 12-16, the cap 72 may have an inner and outermount or connector 80 a, 80 b respectively each on respective internaland external surfaces of the cap 72. At least one and preferably twopairs of locating filaments 82 extend from a filament base 84 that isconfigured to mate with each of the connectors 80 a, 80 b. Theconnectors 80 may comprise a shaped recess or shaped protrusion, withthe mating filament base 84 comprising a protrusion or recess with amating shape. During shipment, as seen in FIG. 12, the filament base 84may be releasably connected to the inside connector 80 a of the cap 72,preferably at the center of the cap 72 so the locating filaments 82extend along the longitudinal axis 16 inside the extension tube 60and/or inside the first tube 36. The filament 82 and its base 84 may beshipped separately, but then they may be more easily separated and lostso it is preferably to ship the parts as a unit. During installation,the cap 72 is removed, the length of tubular passage assembly 10adjusted by cutting the first tube 36 or positioning one or moreextension tubes 60 on the first tube 36.

Referring to FIGS. 1, 10-11 and 13, after the length of the tubularpassage assembly 10 is adjusted, the cap 72 is screwed onto the distalextension tube 60 or latched onto the ridges of the first tube 36—butonly after the connector and locating filaments are removed from theinside of the cap 72 and fastened to the connector 80 b on the outsideof the cap 72 so the locating filaments 82 extend upward along thelongitudinal axis of the tubes and away from the base 12 of the tubularpassage.

When concrete is poured and finished, the locating filaments 82 willstick out of the concrete so the distal end of passage tube assemblycovered by cap 72 can be located. The locating filaments 82 are selectedto be thin enough to bend and not break during troweling of theconcrete, and the connector 80 and filament base 84 are configured andlocated relative to the cap 72 so the locating filaments bend at thejuncture with the connector rather than break during troweling. Nylonmonofilaments about 20 to 40 thousandths of an inch in diameter andabout 2-6 inches in length are believed suitable. The monofilamentscould be color coded to reflect the type of pipe with which the tubularpassage assembly 10 is intended for use, such as red for metal and whitefor plastic. Similarly, tabs could be provided having matching colorcoding. The removable tabs 124 are visible only from the bottom afterthe concrete deck is poured so color coded filaments 82 could provide avisible indicator from the top side of the concrete surface. Since thepipes are preferably run from the bottom up, and since the filaments 82and cap 72 may be lost or attached to the wrong passage assembly 10, theremovable tabs 124 are the preferred identification mechanism.

Referring to FIGS. 12-16, the exterior connector 80 b is preferablylocated in a recess 94 preferably a cylindrical recess centered onlongitudinal axis 16 during use. The recess 94 preferably has rounded orchamfered edges to reduce cutting, damaging or breaking of abuttinglocating filaments 82. The connector 80 b and filament base 84 are sizedso the juncture of the locating filaments 82 with the filament base 84is located below the exterior surface of the cap 72 so that when atrowel blade or float repeatedly bends a filament 82 flat against theconcrete surface the filament does not break off but resiliently resumesits position parallel to the longitudinal axis 16. The exterior, axialfacing surface of the cap 72 may have wrenching recesses 96 into which auser can insert wrenching tools, such as the jaws of channel-lockpliers, in order to help rotate the cap and remove it after concrete hashardened.

Referring to FIG. 12, during shipment, the first extension 60 may beplaced outside of and concentric with the first tube 36, with the lugs70 sliding in channels 52 and then rotated to engage the lower ridges 46or 48 adjacent base 12 to fasten the extension tube 60 to the first tube36. The cap 72 can be threadingly fastened to the threads 66 on thefirst extension tube 60, with the locating filaments 82 inside the tubes36, 60 where they will not be broken easily or lost. The cap 72 preventsdebris from entering the tube from the upper end of the assembly andthus provides a safety guard to protect personnel foot traffic on theunfinished building floor.

Referring to FIGS. 1-9 and 11-12, the flange 17 19 extending outwardfrom the base 12 can be fastened to a support 33, with FIG. 22 showing acorrugated support 33. Deck corrugations can vary from two to six inchesfrom top to bottom. The support 33 may be a flat surface such as aplywood support or other flat support during use. If the diameter of thebase 12 and first tube are large enough so they always extend across atleast two or three adjacent corrugations of a corrugated support 33 thenthe tubular passage assembly 10 is largely self-supporting and theflange 17 may mount to triangular shaped ears of a square with thecircular passage of sidewall 19 having the roughly same diameter as thelength of a square shaped flange 17 and centered in that square flange.If the diameter of sidewall 19 and tube 36 are smaller, then the baseflange 17 must extend over enough corrugations to provide a stablesupport for the tubular passage assembly 10 and to allow fastening tothe corrugated support 33 (FIG. 22). In short, larger flanges 17 may beneeded for tubular passages 10 having smaller diameter passages when thetubular passages are used on corrugated supports 33 rather than flatsupports 33.

Referring to FIGS. 1 and 17-20, if a corrugated support 33 is used, thenremovable stabilizing plates 100 may be attached to a plurality offlanges 17, preferably to opposing flanges 17. One or more, andpreferably a plurality of offset fingers 102 on one side of arectangular stabilizing plate may mate with correspondingly locatedopenings 104 along an edge of one of the base flange 17. Preferably thefingers 17 are generally rectangular strips with rounded distal endsbent to place the rounded distal ends in a plane parallel to but abovethe plane of the stabilizing plate 100. The openings 104 preferably takethe form of slots spaced to correspond with the locations of the fingers102. Each of the rounded distal ends of the fingers 102 pass from thebottom of the flange 17, through a corresponding openings 104 in theflange 17 and rest against the top of the flange 17 to connectstabilizing plates to the flange. The stabilizing plates provide a widerbase to extend across one or more corrugations of the support 33. Asdesired, stiffening ribs 105 may be formed on or in the plates 100.

The fingers 102 engage the top of the flange 17 and the adjacent portionof stabilizing plate 100 engages the adjacent bottom portion of theflange 17 to provide a stable support for the base 12 as long as weightis exerted downward along longitudinal axis 16. If the base 12 is liftedupward along axis 16, the fingers 102 of the stabilizing plate 12rotates about the edges of the openings 104 so the outer end of theplate 100 sags downward and inward toward axis 16. To prevent this aholding latch 106 preferably extends upward from the same side of theplate as the fingers 102 and the holding latch has a notch that engagesan upper side of the base 12, preferably engaging an upper surface ofbase flange 17, to keep the stabilizing plate 100 engaged with theflange 12 and to restrain sagging of the outer edge of the plate 100toward the longitudinal axis 16. A recess, preferably a slot 108 mayextend into an edge of the base flange 17 and be located to correspondwith the holding latch 106 so the holding latch can more securely engagea surface of the base 12 along a portion of the length of the slot 106.

In use, a stabilizing plate 100 is preferably but optionally fastened totwo opposing sides of the base 10 to provide a broader base for thetubular passage assembly 10. The base flange 17 preferably has a recess106 and finger openings 104 on one or more sides, preferably on opposingsides, and more preferably on each of four sides of a rectangular base,where reference to a rectangular base is used herein to include a squarebase.

Referring to FIGS. 1-4, 23 and 24A-24B, two separate but adjacentpassageway extensions 10 may be joined together, preferably at theirbase flanges 17. The base 12 a may have an elongated latch 110 extendingaway from base to engage a mating recess in a different base 12 b. Inthe depicted embodiment the base flange 17 has latch 110 extending fromthe base flange 17, preferably generally horizontally, with a latchingend 112 configured to engage a catching surface 114 on a differentflange 12 b associated with a different base 12 b. The latches 110 andcatching surfaces 114 are located so that if first and second bases 12a, 12 b are placed against each other the latch end 112 a of a firstbase 12 a on flange 17 a can engage the catch 114 b on a second baseflange 17 b to hold the two bases 12 a, 12 b together. Preferably, atleast one side of each base 12 has one latch 110 and one catch 114(e.g., a recess) located toward opposing ends of the at least one side,so that the latches 110 a, 110 b from at least two different baseflanges 17 a, 17 b engage a recess 114 b, 114 a in the other base flange17 b, 17 a to fasten at least the two different base flanges together.Different types of mating projections and recesses can be used,preferably with a male engaging member on one base 12 and a femalemember on a second base 12. While at least two adjacent tubular passageassemblies 10 may be joined this way, the joinder still allowsstabilizing plates 100 to be fastened to the sides of base 17 not joinedby the latches 110 and mating catches 112.

Also shown in FIGS. 23, 24A 24B are a latching members preferably takingthe form of snap lock member 116 a and a mating catch 116 b each locatedon opposing sides of sidewall 19 and located so that the snap lockmembers 116 a on one housing 14 a engage a mating catch 116 b on matinghousing 14 b to latch the housing parts 14 a, 14 b together. The snaplock member and catch provide a fast connection between housing parts 14a, 14 b. The member and catch 116 a, 116 b are located below the bossreceiving the threaded fastener 18, on the split line separating thehousing parts 14 a, 14 b. That split line is located on a planecontaining the longitudinal axis 16.

Referring to FIGS. 17-20, for corrugated supports 33, a hole is cutthrough the corrugation support and the base 12 is positioned over thehole so the longitudinal axis 16 is centered in the hole. An extensiontube 60 is passed upward through the hole in the corrugation andfastened to the bottom of the base 12. Preferably the end of theextension tube 60 having external threads 64 passes through thecorrugation and engages base 12. The base 12 may have mating screwthreads 120 encircling the axis 16 and tubular cylinder 22 ofintumescent material and thus located outward of that cylinder 22 andaccessible from the lower end of the base. The threads 120 are doublelead threads, with one lead on each half 14 a, 14 b of the housing. Toenable the screw threads 120 to extend into the base 12 and stillencircle the tubular cylinder 22 of intumescent material, the retainingclip 24 has annular supporting surface 30 offset downward from tabs 26so that the tabs have a portion extending axially to form an axialoffset accommodating the bottom screw threads 120 with the distal endsof tabs 26 then extending outward through openings 28 in the cylindricalsidewalls 19 of the base 12 that encircle the tubular cylinder 22 ofintumescent material.

As needed, a removable adhesive cover 122 is placed over the bottom ofthe base 12 to keep debris from entering the base during shipment,installation, pouring of the concrete and subsequent application of fireretardant spray. The removable adhesive cover may be removed and placedon the open end of extension tube 60 that is screwed into the bottom ofthe base if desired. Alternatively, separate adhesive covers orremovable caps can be provided. As the extension tube 60 has internalthreads 66, an additional cap 72 could be provided and used. But sincethe bottom opening in tube 60 that is covered by adhesive cover 122 isnot normally expected to have any concrete pushing against the cover122, it need not be as strong as cap 72 onto which concrete may bepoured and onto which workers may step during use.

Referring to FIGS. 2 and 17-20 and especially to FIGS. 2 and 18, thebase flange 17 may have two removable tabs 124 a, 124 b installed intoor formed in the base, preferably in flange 17. One tab 124 a mayindicate metal and the other tab 124 b may indicate plastic. If theshaped diaphragm 40 is selected for use with metal pipe the plastic tab124 b is removed so that a user can see from looking at the remainingtab 124 a on the base 12 that the passage tube is intended for use withmetal pipes. If the shaped diaphragm 40 is selected for plastic pipesthen the metal tab 124 a is removed so that a user can see from lookingat the remaining tab 124 b on the base 12 that the passage tube assemblyis intended for use with plastic pipes. Tabs 124 may be scored,perforated or otherwise surrounded by weakened material so the selectedtab can be punched out, broken off or otherwise removed. Alternatively,the tabs 124 may be separate pieces that are selectively pressed intomating openings 126 in flange 17. This provides a way to readilyidentify at the factory which type of pipe with which the passage tubeassembly is to be used.

Referring to FIG. 25a , the tubular cylinder 22 of intumescent materialis made of a material that expands significantly under heat so as toblock off the space between the pipe and the adjacent parts of theexpandable sleeve 10 which are encased in concrete. Since plastic pipessometimes melt under sufficient heat, the tubular cylinder 22 ofintumescent material may need to expand to fill more than the spacebetween the cylinder 22 and the adjacent pipe as it may need to compressa melting and flexible walled pipe to ensure blockage of gases and waterthrough the expandable sleeve 10. In order to help the tubular cylinder22 of intumescent material expand sufficiently it is believedadvantageous to provide the cylinder 22 with undulating sides formingalternating ridges 128 and valleys 130, with a ridge 128 a on an outersurface of the cylinder 22 being opposite a valley 130 b on an innersurface of the cylinder 22, and a valley 130 a on the outer surface ofthe cylinder 22 being opposite a ridge 128 b on the inner surface.

The height of the undulating ridges 128 relative to the adjacent valley130, and the spacing of the ridges 128 will vary with the diameter ofthe tubular cylinder 22 of intumescent material and the amount ofdesired inward expansion and the type of intumescent material used. Theundulations are evenly spaced to ensure more even expansion. Cylinders22 with an outer diameter of about 2 inches and a wall thickness ofabout ⅛ inch, about 24 undulations and an inner and outer diameterdifference of about ⅜ of an inch are believed suitable for use with apipe having an outer diameter from about ⅝ inch to about 1.3 inches.Cylinders 22 with an outer diameter of about 3¼ inches and a wallthickness of about 0.14 inches, about 24 undulations and an inner andouter diameter difference of about ⅜ of an inch are believed suitablefor use with a pipe having an outer diameter from about 1.4 to about 2.5inches. Cylinders 22 with an outer diameter of about 4¼ inches and awall thickness of about 0.13 inches, about 24 undulations and an innerand outer diameter difference of about ⅜ of an inch are believedsuitable for use with a pipe having an outer diameter from about 2.6inches to about 3.5 inches. Cylinders 22 with an outer diameter of about4.5 inches and a wall thickness of about 0.13 inches, about 24undulations and an inner and outer diameter difference of about ⅜ of aninch are believed suitable for use with a pipe having an outer diameterfrom about 3⅛ inch to about 4.5 inches. Cylinders 22 with an outerdiameter of about 7⅜ inches and a wall thickness of about 0.13 inch,about 24 undulations and an inner and outer diameter difference of about⅜ of an inch are believed suitable for use with a pipe having an outerdiameter from about 5⅛ inch to about 6⅝ inches. A preferred intumescentmaterial for these undulating cylinders 22 is as described in U.S. Pat.Nos. 6,790,893 and 6,645,278.

The undulations on tubular cylinder 22 need not be smoothly undulatingas in FIG. 25a , nor need the undulations extend from opposing sides ofthe wall of the cylindrical tube 22. As shown in FIG. 25b , theundulations may be triangular in cross-sectional shape extending inwardto form ridges 128 b and valleys 130 b. The outer surface of tube 22 issmooth. FIG. 25c shows an intumescent cylindrical ring 22 havinglongitudinal ribs on its inner surface where the ribs 128 and valleys orrecesses 130 where the ribs have a rectangular cross-sectional shape, asdo the valleys. The depicted ridges and valleys 128, 130 are alignedwith longitudinal axis 16, but could be circumferentially aligned, orinclined. The outer surface of the tubular cylinders 22 in FIGS. 25b,25c are smooth, but the outer surfaces could have the same undulationsas the inner surface, or any combination of the depicted undulations.

FIG. 25d shows an intumescent tubular cylinder 22 having a smooth innerwall and a shaped outer wall at the upper edge of the cylinder 22. Inparticular, the tubular cylinder 22 has an outwardly extendingrectangular flange 132 shaped to mate with a corresponding recess 133 ain the sidewall 19 of the modified base 12 a which forms an outwardextending flange 133 b on the outside of the modified base 12 a.Openings 135 are formed in the sidewall 19 at the location of flange 133b and recess 133 a. The shaped flange 132 on the intumescent tube 22fits into the recess 133 a on the sidewall 19 of modified housing 12 aand extends across openings 135.

During use, the openings 135 allow heat from a fire to directly impingeon the intumescent cylinder 22 to more easily precipitate rapidexpansion of the cylinder 22. Further, the intumescent flange 132 andbase flange 133 a provide not only a labyrinth seal restricting moisturepassage between the base 12 a and concrete encasement, but provide for agreater concrete interlock resisting pulling the tubular passage 10through the concrete deck along the longitudinal axis 16. Moreover, theopenings 135 allow the intumescent material of tube 22 to expand todirectly abut the encasing concrete to further interlock the expandedintumescent material to the concrete during heated expansion and thathelps maintain the blockage of the tubular passage 10 from the expandedintumescent material during use. Moreover, the enlarged, outwardextending flange 132 of intumescent material may expand outward as theplastic housing 12 b melts during a fire, further interlocking theexpanded intumescent material to the concrete during heated expansionand that helps maintain the blockage of the tubular passage 10 from theexpanded intumescent material during use. While two openings 135 areshown, any number of openings may be used.

The tubular cylinder 22 of intumescent material is preferably extrudedor molded at a temperature below that at which the material begins toexpand significantly. Alternatively, the material may be used in flatstrips that are wrapped around molds having the desired cylindricalshape, or having an undulating walled cylindrical shape. Still further,strips of material may be impressed on opposing sides to formundulations and the strip then formed into a cylindrical shape. Ifformed of strips, the opposing ends of the strips may be left separate,but adjacent each other to form the cylindrical shape with setting ofthe material retaining that shape, or the adjacent ends may be fastenedby various fasteners such as clips, staples, stakes, adhesive, tape,etc. to maintain the shape. The strips of material formed into acylinder may also have the outer surface wrapped with and fastened to acylindrical tube of material to maintain the shape.

For assembly, the appropriate base 12, tubular cylinder 22 ofintumescent material, retaining clip 24 and diaphragm seal 40 areselected for the desired type of pipe and range of pipe sizes. Thetubular cylinder 22 of intumescent material is placed into the annularbase 30 of clip 24 and the tabs 26 are inserted through the slots 28 inone half of housing 14 to wedge the cylinder 22 into place against thelip 20 and against the interior of the corresponding sidewall 19. Thenthe other half of the housing 14 is then aligned with the remaining tabs26 and the two parts of the housing 14 a, 14 b are joined and fastenedtogether in abutting relationship to form a base assembly 12. The tabs26 on retaining clip 24 are bent to inhibit removal and lock the tubularcylinder 22 of intumescent material in place against vertical motionalong one direction of longitudinal axis 16. Advantageously, bendingtabs 26 also offer increased security in retaining the assembly 10within the poured concrete, as for example, if the plastic parts areexposed to fire or fire-fighting activities such as sprays of highpressure water. Somewhere along the assembly process, the appropriatetab 124 is either removed or inserted, as the case may be, so that thetab in place on the tubular passageway 10 indicates whether the assembly10 is for use with metal or plastic pipes, resulting in a base assemblywith visible indicia indicating the type of pipe application suitablefor use with the base assembly.

After the base assembly 12 is completed, the selected diaphragm seal 40is then placed on top of the lip 20 of base 12, and the first tube 36 isattached to the base 12, preferably by engaging double lead threads 35on the tube 36 with mating threads 34 on the base 12. The stops 38 a, 38b abut to limit rotation with the parts being sized so the limit stops38 a, 38 b engage when the outer periphery of diaphragm seal 40 issecurely clamped between base 12 and first tube 36, and preferablyclamped between lip 20 on base 12 and inward extending flange 39 on thefirst tube 36. The limit stops 38 a, 38 b also locate the distal end offirst tube 36 a known distance from the base flange 17, preferably aknown distance from the bottom of the base flange 17, with the visibleindicia 50 on the tube 36 reflecting distances along longitudinal axis16 from that base flange 17. The base assembly may include the base 12,retainer 24 and intumescent tube 22 and it may be shipped separately oras part of a kit. The base assembly, diaphragm seal 40 and first tube 36may be shipped as a separate assembly or as parts of a kit, with orwithout cap 72 and filament 82 and its mount 84.

But preferably a first extension tube 60 is fit over the first tube 36and fastened thereto by lugs 70 sliding along channels 52 and rotated toengage ridges 46, 48, with cap 72 fastened to the distal end of theextension tube 60 as in FIG. 12. The filament base 84 and filament(s) 82are preferably connected inside the assembly (FIGS. 12, 14). The openbottom in base 12 may be left open, or covered by another cap 72 or by aremovable cap 122. Additional extension tubes may be shipped with thisassembly. The base assembly may be shipped by itself, or shipped as akit with the first tube 36, cap 72, cover 122, one or more extensiontubes 60 and one or more (preferably 2 or 4) stabilizing plates 100, orany combinations thereof.

A user takes the assembled base 12 and verifies it is for the type ofpipe intended for use with the passage assembly 10 by looking at tabs124. The user then adjusts the first tube 36 to the desired length bycutting the tube 36 between ridges 46, 48 using the visible indicia 50as a guide, or by adjusting the relative position of the first extensiontube 60 on the first tube 36, again using visible indicia 50 as a guide.As needed, additional extension tubes 60 may be added as described aboveto increase the length, with the position of the first extension tube 60relative to the first tube 36 reflecting fine adjustments on the fixedlength provided by the joined extension tube(s) 60. After adjusting thelength, the user fastens the base 12 to the support 33 onto whichconcrete is to be poured. As needed, the user may attach one or morestabilizing plates 100. Typically, fasteners such as screws (forcorrugated supports 33 and nails for wooden supports 33) pass throughholes 32 in the flange 17 or stabilizing plates 100 to fasten thepassage tube assembly 10 to the support 33. If a corrugated support 33is used, a hole is cut through the support 33 and the user fastens anextension tube to the bottom of base 12 by removing any protectivebottom cover (e.g., cap 72 or cover 122) and then engaging threads 64 ofextension tube 60 with threads 120 in the bottom of base 12 so theextension tube depends from the base 12. The end of extension tube 60 isthen passed through the hole in the support 33 with the distal end ofthe depending extension tube 60 covered by cap 72 or cover 122, or openas the user desires. The flange 17 and/or stabilizing plates 100 arethen fastened to the corrugated support 33.

Shortly before concrete is poured, the cap 72 is removed from the topend of the passage tube assembly. The base 84 and filament(s) 82 areremoved from the bottom of the cap and affixed to the top of the cap 72,as shown in FIGS. 9-11, 17, 20 and 22 and the cap is then put back onthe tube assembly so the locating filaments stick upward. Concrete isthen poured, with the tubular passage assembly 10 forming a casingentrained in the concrete. The ridges 46 a, 46 b and the variousprojections and changes in contour on the base 12 and tubes 36, 60 helpembed the parts in the concrete so as to inhibit removal. Optionalridges 134 may extend outward from the stepped portion 37 of the firsttube 36 to help embed the parts in the concrete, and act as labyrinthseals against the passage of moisture between the passage tube assembly10 and the concrete encasement. The depending extension tube 60 helpsprevent the concrete from entering the tubular assembly 10 from betweenthe top and bottom of the corrugations in the support 33.

After the concrete is finished and hardened sufficiently, the locationof the passage assembly 10 may be identified by the filament(s) 82sticking above the concrete. The cap 72 may be removed by inserting thejaws of a channel lock pliers in the wrenching recesses 96 and rotatingthe cap. The cover 122 or cap may be removed from the bottom of base 12or the depending extension tube 60 fastened to the base. The workers canthen pass pipes through the tubular passage assembly by passing themupwards through the opening 42 of flexible diaphragm seal 40. Theflexible, funnel shaped seal 40 allows some variation in pipe diameterand location so as to make it easier for workers to install the pipesbetween floors and to accommodate misalignments.

The ridges 46, 48 extend radially outward from the cylindrical firsttube 36. The ridges 46, 48 extend for a majority of the length of thefirst tube, and preferably extend the entire length or substantially theentire length of the tube from the stepped portion 37 to the upperdistal end of the tube. By substantially the entire length is meantabout 90 percent or more of the specified length. The ridges 46 areaxially offset from the ribs 48, such that the distance between ribs 46may be measured in inches and the distance between ribs 48 may bemeasured in millimeters or centimeters. The space between the adjacentridges 46, 48 is preferably the same within both sets of ridges 46, 48.The space between the adjacent ridges 46, 48 is preferably larger thanthe width of the respective ribs measured along the longitudinal axis16, with the space advantageously being about the width of a saw bladeused on construction sites.

Except for the seal 40, the various other parts of the passage tubeassembly 10 are preferably made of plastic, with ABS, PVC orpolypropylene plastic being preferred. The extension tubes 60 and firsttube 36 are preferably each about 5.5 inches long and overlap about oneinch with the base 12 in releasable attachment thereto. The base 12 addsabout two inches to the height of the assembly so that a base 12 andfirst tube 36 are about 7.5 inches from the bottom of base flange 17 tothe distal end of the first tube 36, with a cap adding about ⅛ inch ofadditional height that is removed after concrete is poured. Adding oneextension tube 60 increases the assembly height to about 12 inches fromthe deck or support, upon which the bottom surface of base flange 12rests. While the extension tube 60 is about 5.5 inches long, there isabout 0.5 inches of engaged threads 64, 66 on the two mating parts.Thus, the distance from the bottom of base 12 to the top of the assemblywith tubes 36, 60 represents the length of the passage from the uppersurface of the deck

If a fire occurs, the tubular cylinder 22 of intumescent material willexpand under a suitable temperature to block off air flow through theinside of the tubular passage assembly 10. If flooding occurs, theflexible diaphragm seal 40 seals against the pipe passing throughopening 42 of the seal 40, with the initial water pressing the upwardlyextending funnel portion 44 against the pipe so as to improve the sealand increase the weight of water needed to invert the seal and/or allowleakage past the seal

Although these inventions have been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present inventions extend beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the inventions and obvious, modifications and equivalentsthereof. In addition, while several variations of the inventions havebeen shown and described in detail, other modifications, which arewithin the scope of these inventions, will be readily apparent to thoseof skill in the art based upon this disclosure. It is also contemplatedthat various combination or sub-combinations of the specific featuresand aspects of the embodiments may be made and still fall within thescope of the inventions. It should be understood that various featuresand aspects of the disclosed embodiments can be combined with orsubstituted for one another in order to form varying modes of thedisclosed inventions. Thus, it is intended that the scope of at leastsome of the present inventions herein disclosed should not be limited bythe particular disclosed embodiments described above.

What is claimed is:
 1. A kit for forming a tubular passage through apoured concrete deck, comprising: a base assembly having a base formedof two opposing housing portions fastened together to form a housinghaving a cylindrical sidewall portion extending along a longitudinalaxis and containing a tubular cylinder of intumescent material adjacentthe cylindrical sidewall portion, the tubular cylinder of intumescentmaterial encircling the longitudinal axis and having its motion limitedin a first direction along the axis by the housing and having movementin an opposing direction along the axis limited by a clip engaging thehousing; a flexible diaphragm seal having a central opening selected toseal against a range of pipe diameters during use, the seal having afunnel portion between an outer periphery and the central opening,wherein the funnel shape includes a sidewall forming the central openingwhich sidewall is curved in cross-section toward the longitudinal axisand forms a circle of revolution; and a first cylindrical tubeconfigured to fasten to a top of the base assembly during use andencircle the longitudinal axis during use, the first tube and base beingconfigured to clamp a periphery of the flexible diaphragm between themsufficiently to form a fluid tight seal.
 2. The kit of claim 1, whereinthe first tube has a plurality of outwardly extending, equally spacedridges on an exterior surface thereof and extending along a majority ofa length of the first tube and extending less than a majority of acircumference of the first tube, and further including: a firstcylindrical extension tube having a first end configured to fit over thefirst tube and having at least one lug configured to engage a selectedone of the plurality of outwardly extending ridges to releasably fastenthe first extension tube to the first tube.
 3. The kit of claim 2,wherein the first tube fastens to the top of the base by a double leadthreaded connection, the base having internal, double lead threads on abottom thereof which threads encircle a lower portion of the tubularcylinder of intumescent material and are configured to threadinglyengage mating threads on the first cylindrical extension tube.
 4. Thekit of claim 2, further comprising a cap having a skirt having an innersurface configured to releasably engage the ridges and having an outersurface configured to releasably engage an inward facing surface of thecylindrical extension tube, the cap having an exterior surface facingalong the longitudinal axis which exterior surface contains a recessedconnector configured to releasably engage a base from which extends atleast one filament having a length greater than about one inch, the basereleasably engaging the filament in the recess and below the outersurface of the cap.
 5. The kit of claim 2, further comprising a flexiblefilament having a base and a length of about one to several inches long,and a cap having a skirt sized to engage a distal end of the firstcylindrical tube, the cap having an exterior surface facing along thelongitudinal axis and containing a recess configured to releasablyreceive the base of the filament.
 6. The kit of claim 5, wherein the capskirt has an inner surface configured to releasably engage the ridgesand has an outer surface configured to releasably engage an inwardfacing surface of the cylindrical extension tube.
 7. The kit of claim 1,wherein the funnel portion has a curved sidewall.
 8. The kit of claim 1,further including a cap for a distal end of the first cylindrical tube,the cap having an exterior surface facing along the longitudinal axisand an opposing interior facing surface, the kit further including aflexible filament having a base and a length of about one to severalinches long, the cap having a recess in the exterior surface of the capcontaining a connector to releasably connect to the base of the filamentwithin the recess, the cap having a projection extending from theinterior surface of the cap forming an interior connector to releasablyconnect to the base of the filament.
 9. The kit of claim 1, wherein thefirst tube further includes a first set of parallel ridges extendingoutward from the first tube with each of the ridges in a planeorthogonal to the longitudinal axis, the first set of ridges eachextending less than half way around the first tube; a second set ofparallel ridges extending outward from the first tube with each of theridges in a plane orthogonal to the longitudinal axis, the second set ofridges each extending less than half way around the first tube andlocated on an opposing side of the first tube than the first set ofridges, the first and second ridges having ends spaced apart to definefirst and second longitudinal channels on opposing sides of the firsttube.
 10. The kit of claim 9, wherein the first tube further comprises afirst set of visible indicia adjacent a plurality of the first set ofridges defining a distance from the bottom of the base to the visibleindicia associated with each of the plurality of the first set ofridges.
 11. The kit of claim 10, wherein the first tube furthercomprises a second set of visible indicial adjacent a plurality of thesecond set of ridges defining a distance from the bottom of the base tothe visible indicia associated with each of the plurality of the secondset of ridges, wherein at least one of the first and second set ofindicia is a distance specified in metric or English distance units. 12.A kit for forming a tubular passage through a poured concrete deck,comprising: a base having a cylindrical sidewall portion extending alonga longitudinal axis and containing a ring of intumescent materialadjacent the cylindrical sidewall portion, the ring of intumescentmaterial encircling the longitudinal axis; a flexible diaphragm sealhaving a central opening selected to seal against a range of pipediameters during use, the seal having a funnel portion between an outerperiphery and the central opening, with the funnel portion having asidewall forming the central opening which sidewall is curved incross-section toward the longitudinal axis and forms a circle ofrevolution; and a first cylindrical tube configured to fasten to a topof the base assembly during use and encircle the longitudinal axisduring use, the first tube and base being configured to clamp aperiphery of the flexible diaphragm between them.
 13. The kit of claim12, wherein the funnel portion has a curved sidewall.
 14. The kit ofclaim 12, wherein the first tube has a plurality of outwardly extending,equally spaced ridges on an exterior surface thereof and extending alonga majority of a length of the first tube and extending less than amajority of a circumference of the first tube.
 15. The kit of claim 14,further including a first cylindrical extension tube having a first endconfigured to fit over the first tube and having at least one lugconfigured to engage a selected one of the plurality of outwardlyextending ridges to releasably fasten the first extension tube to thefirst tube.
 16. The kit of claim 12, wherein the first cylindrical tubehas a plurality of outwardly extending, equally spaced ridges on anexterior surface thereof and extending along a majority of a length ofthe first cylindrical tube, and further including a cap sized to close adistal end of the first cylindrical tube, the cap having a skirt with aninner surface configured to releasably engage the ridges.
 17. The kit ofclaim 14, further including a cap for a distal end of the firstcylindrical tube, the cap having an exterior surface facing along thelongitudinal axis, and further including a flexible filament having abase and a length of about one to several inches long, the cap having anexterior surface facing along the longitudinal axis and containing arecess within which is a connector releasably receiving the base of thefilament within the recess during use of the filament.
 18. The kit ofclaim 17, wherein the cap has a cap skirt having an inner surfaceconfigured to releasably engage the ridges and has an outer surfaceconfigured to releasably engage an inward facing surface of acylindrical extension tube during use.
 19. The kit of claim 12, whereinthe base has a base mounting flange extending outward from the base at abottom end of the base.
 20. The kit of claim 12, further including atleast one stabilizing plate releasably connectable to a base mountingflange extending outward from the base.
 21. The kit of claim 12, furtherincluding a cap for a distal end of the first cylindrical tube, the caphaving an exterior surface facing along the longitudinal axis and anopposing interior facing surface, the kit further including a flexiblefilament having a base and a length of about one to several inches long,the cap having a recess in the exterior surface of the cap containing aconnector to releasably connect to the base of the filament within therecess, the cap having a projection extending from the interior surfaceof the cap forming an interior connector to releasably connect to thebase of the filament.
 22. The kit of claim 12, wherein the first tubefurther includes a first set of parallel ridges extending outward fromthe first tube with each of the ridges in a plane orthogonal to thelongitudinal axis, the first set of ridges each extending less than halfway around the first tube; a second set of parallel ridges extendingoutward from the first tube with each of the ridges in a planeorthogonal to the longitudinal axis, the second set of ridges eachextending less than half way around the first tube and located on anopposing side of the first tube than the first set of ridges, the firstand second ridges having ends spaced apart to define first and secondlongitudinal channels on opposing sides of the first tube.
 23. The kitof claim 22, wherein the first tube further comprises a first set ofvisible indicia adjacent a plurality of the first set of ridges defininga distance from the bottom of the base to the visible indicia associatedwith each of the plurality of the first set of ridges.
 24. The kit ofclaim 23, wherein the first tube further comprises a second set ofvisible indicial adjacent a plurality of the second set of ridgesdefining a distance from the bottom of the base to the visible indiciaassociated with each of the plurality of the second set of ridges,wherein at least one of the first and second set of indicia is adistance specified in metric or English distance units.